JP2001158025A - Method for manufacturing cellular phenol resin panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a cellular phenol resin panel which prevents an occurrence of poor adhesion between a covering member or a reverse covering member and a cellular phenol resin and an occurrence of an unstable shape of a product and to prevent formation of a flaw in a product, a decrease of heat insulation effect and water absorption in a molded item without an increase of a complicated process and an increase of a material cost. SOLUTION: The method includes a process of supplying a liquid mixture of a foamable phenol resin to a continuously conveyed covering member, a process of further supplying a reverse covering member to form a laminate, a process of continuously making openings passing through the reverse covering member and the resin layer by means of a perforator to instantly release a gas stored inside when the laminate is passed through a heating furnace and a process of proceeding and completing a hardening reaction to clog the resin layer portion of the opening on the reverse covering member.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a phenolic resin foam panel having a laminated structure in which a phenolic resin foam is sandwiched between a front surface material and a back surface material, and an apparatus for manufacturing the same.

[0002]

2. Description of the Related Art Phenolic resin foam panels are frequently used as heat insulating panels and outer wall materials. In the continuous production of phenolic resin foam panels, there has been a problem of occurrence of defective bonding products and unstable shapes between the front and back surface materials and the phenolic resin foam. It is known that these factors are due to water vapor in the phenol resin and the curing agent, water vapor resulting from condensed water, and pressure due to the foaming agent during molding of the phenol resin foam. As a preventive measure, it is known that external release of gas inside a molded article is extremely effective, and various measures have been proposed. In JP-A-58-3858 and JP-A-58-3860, a water-absorbing sheet such as kraft paper or cloth is attached to the bonding interface, or a hollow shirasu balloon or the like is added to a phenol resin foam. It has been reported that by absorbing the moisture inside the molded product, a heat-insulated panel from which gas has been released to the outside can be obtained. In the case of these panels, the number of complicated steps in the molding operation increases, and the material cost also increases.

[0003] Japanese Patent Publication No. 4-2097 discloses that a large number of small holes are formed in one side material of a phenolic resin foam insulation panel.
A production method has been reported in which moisture generated during foaming or moisture remaining after molding is easily discharged. With this manufacturing method, poor adhesion between the back material and the phenol resin foam,
Insufficient removal of water from the foam is improved to some extent, but the above-mentioned problems continue to exist on the surface material side where no small holes are formed.

Japanese Patent Application Laid-Open No. 4-360950 reports an architectural panel in which a plurality of through holes are formed from the back surface material toward the back side of the surface material. Since this panel has a plurality of through-holes, it has the effects of preventing deformation of the product, preventing peeling of the face material from the resin foam, forming a uniform foam over a long period of time, and preventing explosion in a fire. However, on the other hand, the plurality of through holes may damage the product and cause a decrease in the heat insulating effect.
In addition, the organic acid contained in the phenolic resin curing agent enhances the water absorption action into the molded product through the through-hole, and when the absorbed moisture oozes out, the aluminum vaporized kraft paper due to its acidity Etc. may erode the backing material. Japanese Patent Application Laid-Open No. 8-291613 reports a panel in which a combination of a plurality of through holes and a breathable waterproof sheet prevents deformation of the panel while maintaining breathability, and also improves waterproofness. In this case, there is a risk of a process for incorporating the breathable waterproof sheet and an increase in cost, and a device for preventing the adhesive for the breathable waterproof sheet from blocking the through holes is also required.

[0005]

In order to prevent the occurrence of defective bonding products and unstable products between the front and back surface materials and the phenol resin foam, the phenol resin and the moisture or condensed water in the curing agent must be removed. It is most effective to externally release the gas generated at the time of molding the phenolic resin foam from the resulting water vapor and the foaming agent. However, it is not desired that the number of complicated steps be increased or the material cost is increased. In addition, the shallow small holes are incomplete in the outgassing of the gas, while the through holes are suitable for the outgassing of the gas. There is a problem such as a water absorption effect on water.

According to the present invention, it is possible to prevent the occurrence of defective bonding products and unstable shapes of the phenolic resin foam between the front and back surfaces and the phenol resin foam without increasing the number of complicated steps and the cost of materials.
A manufacturing method that can prevent the formation of scratches on the product, a decrease in the heat insulating effect, and also prevent the water absorption action in the molded product, that is, by piercing the phenol resin foam at an intermediate stage during the molding of the phenol resin foam, sufficient It is an object of the present invention to provide a method for producing a phenolic resin foam panel in which gas is externally released and a resin layer portion at an opening is closed in a subsequent curing reaction.

[0007]

Means for Solving the Problems The present inventors have paid attention to the curing reaction step in the production of a molded article of a phenolic resin foam, and have a sufficient effect to prevent the occurrence of defective bonding products and products with unstable shapes. It has been found out at what step the perforation for gas external release should be performed in order for the external release of the gas to be performed. It has also been found that the portion of the resin layer at the opening formed by the perforation for external release of gas can be closed in a subsequent curing reaction step, and the present invention has been completed.

That is, according to the present invention, a foamable phenol resin mixed liquid is discharged onto a surface material which is continuously transferred, and a back surface material is further continuously supplied and laminated on the resin mixed liquid. Is formed, and the laminated continuum is passed through a single heating furnace while being pressed from the upper and lower surfaces thereof, and a plurality of openings penetrating the back material and the resin layer by a punch installed in the middle of the single heating furnace. Are continuously provided, the gas component staying inside the laminated continuum is instantaneously released to the outside, and the laminated continuum having a plurality of openings on the back material side is continuously pressed from the upper and lower surfaces while a single type. A method for manufacturing a phenolic resin foam panel, characterized by closing a resin layer portion having a plurality of openings through a heating furnace and completing a curing reaction at the same time. Further, the continuous perforation process by the perforator described above is a phenolic resin curing reaction step in a single heating furnace,
A method for producing a phenolic resin foam panel, which is performed between a gel time and a rise time.

[0009] The present invention also provides a laminated continu- ous body by discharging a foamable phenolic resin mixture onto a surface material that is continuously con- veyed, and further continuously supplying a back surface material onto the resin mixture. Is formed, and the laminated continuum is passed through a single heating furnace while being pressed from the upper and lower surfaces thereof, and a plurality of openings penetrating the back material and the resin layer by a punch installed in the middle of the single heating furnace. Are continuously provided, the gas component staying inside the laminated continuum is instantaneously released to the outside, and the laminated continuum having a plurality of openings on the back material side is continuously pressed from the upper and lower surfaces while a single type. A phenolic resin foam panel manufactured by a manufacturing method, wherein a phenol resin foam panel manufactured by a manufacturing method is characterized in that a heating furnace is passed to close a portion of a resin layer having a plurality of openings and at the same time complete a curing reaction.

Further, according to the present invention, a foamable phenol resin mixed liquid is discharged onto a surface material which is continuously transferred, and a back surface material is further continuously supplied and laminated on the resin mixed liquid. Is formed, and the laminated continuum is passed through a single heating furnace while being pressed from the upper and lower surfaces thereof, and a plurality of openings penetrating the back material and the resin layer by a punch installed in the middle of the single heating furnace. Are continuously provided, the gas component staying inside the laminated continuum is instantaneously released to the outside, and the laminated continuum having a plurality of openings on the back material side is continuously pressed from the upper and lower surfaces while a single type. A continuous production apparatus for a phenolic resin foam panel, characterized in that the resin layer is closed at a plurality of openings and the curing reaction is completed at the same time through a heating furnace.

In the present invention, it is most important to select the timing for performing the perforation for external release of gas. First, it is necessary that the phenolic resin foam has been cured to some extent in the previous steps, and then it is necessary to release enough gas to prevent the occurrence of defective bonding products and unstable shapes. It is necessary to provide sufficient subsequent curing reaction steps to close the opening due to drilling.

[0012] The curing reaction of the phenolic resin during the production of a phenolic foam molded article is generally controlled in the following steps. First step “Cream time” Start time of vaporization of foaming agent Second step “Gel time” Transition time to stringy adhesive Third step “Rise time” End of foaming behavior Fourth step “Tack free time” Adhesion Disappearance time As the curing reaction proceeds in such a step, the step particularly related to the adhesiveness is the time period from the second step to the third step, and the gas component staying in this time period Instantaneously to the outside is extremely effective in preventing adhesion failure. Also, the opening in this time slot, although the opening of the backing material itself is left, the opening in the phenolic resin foam layer may be closed with the progress of the subsequent curing reaction of the resin. I was assured. From this result, the position where the drilling machine is installed in the middle of the single-type heating furnace is located between the portion corresponding to the gel time which is the second step during the curing reaction and the portion corresponding to the rise time which is the third step. Must be set.

On the other hand, when the installation position of the drilling machine in the single heating furnace is fixed, the reaction speed of the phenolic resin curing reaction is adjusted to perform the timing for performing the drilling for the external release of gas. Can be optimized. In general, the reaction rate of the phenolic resin curing reaction is adjusted by controlling the amount of the curing catalyst used, the temperature of the heating furnace, the temperature of the resin liquid mixed and discharged, the temperature of the metal molding, and the production line. It can be easily adjusted by controlling the operating speed of the system.

According to the present invention, it is possible to prevent the occurrence of defective bonding products between the surface material and the back surface material and the phenolic resin foam and the shape-unstable products without requiring an increase in complicated steps and a rise in material costs. This makes it possible to prevent the formation of flaws, a decrease in the heat insulating effect, and a water absorption effect in the molded product.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Surface materials usable for the phenolic resin foam of the present invention include color steel plates, color aluminum plates, copper plates, titanium plates, color stainless steel plates, ceramic plates, gypsum boards, cement plates, and synthetic resin plates. And decorative plywood. Examples of usable back surface materials include aluminum-deposited kraft paper, asbestos paper, sheet-like kraft paper, various laminated papers, and synthetic resin sheets.

A typical phenolic foam panel is metal siding. Metal siding is a building material that is frequently used as a building exterior wall material that features light weight and high heat insulation, and is used as a semi-incombustible material in phenol foam-filled products in addition to light weight and high heat insulation. . For metal siding, a processed steel sheet, commonly called a color steel sheet, which is colored and painted on a steel sheet coated with zinc or zinc alloy, is formed into a shape suitable for building materials by an embossing machine or molding machine, and a foam layer is formed inside It will be commercialized.

The phenolic resin foam used in the present invention may be a commonly used resol type phenolic resin foam or a benzylic ether type phenolic resin foam. As the blowing agent, halogenated hydrocarbons and water can be used alone or in combination. In addition, various additives such as a surfactant and a flame retardant can be used in combination.

FIG. 1 shows an example of an apparatus for continuously producing a phenolic resin foam panel according to the present invention. A surface material continuous supply device 1, a foaming phenol resin mixed liquid discharger 3, a back material lamination supply device 4, a single heating furnace 5, a punch 6, and a cutting machine 7 are arranged in this order. The preheater 2 is provided between a continuous supply device for the surface material and a discharger for the foamable phenol resin mixed liquid, and is for preheating the surface material. The back material lamination supply device 4 has an uncoiler 41 wound around the back material and a guide roller 42, whereby the back material is continuously laminated and supplied on the resin mixture discharged onto the front material. This is an apparatus for supplying a continuous laminate. The single heating furnace 5 has a pressing and conveying device in which a conveyor 51 and a belt conveyor 52 are vertically opposed to each other with a predetermined gap.

The heating furnace for controlling the forming and curing reaction of the phenolic resin is a furnace capable of heating while maintaining the shape of the molded product. The molded product is continuously sandwiched between upper and lower conveyors. It often takes the form of running, commonly known as a double conveyor system. As the heating furnace management, various methods such as a single heating furnace system shown in the present invention and a system in which one heating furnace and one heat insulation furnace are connected are devised.

The operation of the apparatus shown in FIG. 1 will be described. The surface material is continuously fed from the surface material continuous supply device 1 to the line. The mixed liquid discharger 3 is a device that discharges a predetermined amount of a foamable phenol resin mixed liquid onto a surface material, and includes one or a plurality of discharge nozzles. A layer of the resin mixture is sandwiched between the surface material and the back material by laying a back material continuously supplied from the back material lamination supply device 4 on the discharged resin mixture. A body is formed. The laminated continuous body is conveyed through the single heating furnace 5 while being pressed from the upper and lower surfaces and maintaining a predetermined thickness. During this time, the resin mixture of the continuous laminate is uniformly spread between the front surface material and the back surface material, is heated via the conveyor 51 and the belt conveyor 52, reaches a predetermined thickness, and reaches immediately before the rise time. Therefore, the punch 6 continuously provides a plurality of openings penetrating the back surface material of the phenolic resin foam panel and the resin layer, and instantaneously discharges the gas staying inside the laminated continuous body to the outside. Subsequently, the resin layer passes through the single heating furnace 5 and is closed by a pressing / conveying device comprising a belt conveyor, and the curing reaction is completed at the same time as the resin layers at the plurality of openings are closed. The continuous laminated body continuously fed from the single heating furnace 5 is cut into a predetermined size by the cutting machine 7 to be a phenolic resin foam panel product.

The drill 6 used in the present invention is installed in the middle of the single heating furnace 5. In a single heating furnace, the surface material is placed on the lower side, the phenolic resin mixture is discharged onto it, and the backside material is further laminated and supplied continuously on the resin mixture to form a laminated continuous body. Therefore, the drilling machine is installed on the upper side of the phenolic resin foam panel, lowers the cone vertically from above toward the surface of the backing material, and an opening that penetrates the backing material and the resin layer to the extent that the cone does not contact the surface material It is preferred to make a part. FIG. 2 shows an example of a punch and a method of attaching the punch.

FIG. 2 shows an example in which a drilling machine is installed in the middle of a single heating furnace. The drilling machine 6 operates continuously according to the flow of the conveyor 51. The cone 61 moves up and down in amplitude,
A plurality of openings penetrating the back material of the phenolic resin foam panel and the resin layer are continuously provided, and the gas staying inside the laminated continuous body is instantaneously released to the outside. The perforation interval is controlled by the perforator control box 62. Also,
The drilling machine is designed to stop when the conveyor 51 stops. When implementing on a twin-screw conveyor,
A seam may be provided only on the upper side of the twin-screw belt conveyor, and the punch may be located there.

The diameter of the opening to be opened by the above-mentioned punch is suitably about 0.5 mm to 2.7 mm. The number of openings is suitably about 2 / m2 to 150 / m2. The depth of the opening is selected according to the thickness of the phenolic resin foam panel, but it is better to open the opening as deep as possible within a range where the cone does not reach the back surface of the surface material. If the opening is shallow, the external release of gas will be insufficient, and it will not be possible to prevent the occurrence of defective bonding products or unstable shapes between the front and back surface materials and the phenolic resin foam.

[0024]

The present invention will be specifically described below with reference to examples and comparative examples. [Example 1] Production example of metal siding A coated steel plate having a thickness of 0.27 mm was mechanically formed in accordance with the standard design, and the formed steel plate was heated to 70 ° C in a preheating furnace using the apparatus shown in FIG. And then drop a foaming resin mixture of the composition described below onto it, immediately cover it with a kraft paper and aluminum foil-bonded backing material, guide it to a single heating furnace, and react at 80 ° C. After the gelling step, the holes were continuously pierced at a rate of 10 holes / m2 with a piercing cone having a diameter of 1.5 mm. The metal siding was then produced by subsequent curing of the resin at 80 ° C. in a single heating furnace. The foamable phenol resin mixture is a mixture of a resole type phenol resin, a foaming agent (dichloromethane), a foam stabilizer, and an aromatic sulfonic acid catalyst.

[Comparative Example 1] Perforation before gel time Metal siding was produced by the same production method as in Example 1, except that perforation was carried out before reaching the gelation stage in a single heating furnace.

[Comparative Example 2] Drilling after rise time Metal siding was manufactured by the same manufacturing method as in Example 1 except that drilling was performed after the rise time in a unitary heating furnace.

[Example 2] Adhesion test with back surface material The back surface material of the metal siding obtained by the production method of Example 1 and Comparative Examples 1 and 2 was cut into a square of 25 cm on a side and peeled off. The foam layer area adhered to the back material was observed. The results are shown in [Table 1].

[Table 1] Adhesiveness to back surface material << Test sample >> << Adhesiveness >> Example 1 Good adhesiveness Comparative example 1 Overall poor adhesion (prominent gas retention) Comparative example 2 Partial adhesion failure (Slight gas retention) Yes)

Example 3 Adhesion Test with Surface Material The metal siding obtained by the production method of Example 1 and Comparative Examples 1-2 was peeled off as it was, and the foam layer was adhered to the entire surface material. The area was observed. The results are shown in [Table 2].

[0030]

Example 4 Dimensional Stability Test The metal siding obtained by the production method of Example 1 and Comparative Examples 1 and 2 was cut into a length of 60 cm, and was cut at 20 ° C. for 6 hours for 8 hours.
Five cycles of a heating / cooling cycle test were performed under the temperature conditions of 0 ° C. for 6 hours and 20 ° C. for 6 hours, and deformation was observed. The results are shown in [Table 3].

[0032]

Example 5 Water Penetration Test into Foam Resin Layer A colored water-based ink was dropped on the backing material perforated trace of the metal siding obtained by the production method of Example 1 and Comparative Examples 1-2. Water penetration into the foam layer was observed. The observation results after 3 hours have been shown in [Table 4].

[0034]

[0035]

According to the method of manufacturing a phenolic resin foam panel of the present invention, a plurality of openings penetrating the back material and the resin layer are continuously formed by a punching machine installed in the middle of a unitary heating furnace. The gas which stays and is released to the outside instantly,
Since the curing reaction is completed at the same time as closing a plurality of openings during the subsequent passage through the unitary heating furnace, the phenolic resin foam panel of the product has poor adhesion or poor shape between the surface material and the backside material and the phenolic resin foam. Generation of stable products can be prevented. Further, it is possible to prevent the formation of scratches on the product, a decrease in the heat insulating effect, and an effect of absorbing water into the molded product. Further, according to the present manufacturing method, it is possible to obtain the above-described effects without increasing the number of complicated steps and the cost of materials.

[Brief description of the drawings]

FIG. 1 is a plan view showing an apparatus for continuously producing a phenolic resin foam panel according to the present invention.

FIG. 2 is a perspective view showing an apparatus in which a drilling machine according to the present invention is installed in the middle of a unitary heating furnace.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Surface material continuous supply apparatus, 2 ... Preheater, 3 ... Discharge machine of foaming phenol resin mixed liquid, 4 ... Backside material lamination supply apparatus, 41 ... Uncoiler, 42 ... Guide roller, 5 ... Unity heating furnace, 51: conveyor, 52: belt conveyor,
6: drilling machine, 61: drilling cone, 62: drilling machine control box, 7: cutting machine.

Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat II (Reference) B29K 105: 04 B29K 105: 04 B29L 31:10 B29L 31:10 (72) Inventor Tadayoshi Haneda Daikoku, Tsurumi-ku, Yokohama-shi, Kanagawa 7F, No. 43, Ho Futaya Chemical Industry Co., Ltd. Yokohama Plant F-term (reference) 2E001 DD01 GA24 GA42 HA01 HA03 HA14 HB02 HB03 HB04 HB05 HB08 HC02 HC08 HD02 HD11 4F100 AB03A AB10C AB33C AK33B AS00A AS00C BA03 BA07 BA10A BA10C DG10 EJ082 EJ172 EJ332 EJ421 EJ422 EK092 GB07 JL11 4F204 AA37 AB02 AD03 AD06 AD08 AD29 AD35 AG03 AG20 AH47 AH48 AM32 FA11 FB02 FB13 FN11 FN12 FN15 FN17 FN30 FQ22 FQ40

Claims (4)

[Claims] 1. A foamable phenolic resin mixture is discharged onto a surface material that is continuously transferred, and a backside material is continuously laminated and supplied on the resin mixture to form a laminated continuous body. A plurality of openings penetrating through the back material and the resin layer are continuously formed by passing the laminated continuous body through a single heating furnace while pressing the laminated continuous body from the upper and lower surfaces thereof, and using a punching machine installed in the middle of the single heating furnace. Provided, the gas component staying inside the laminated continuum is instantaneously released to the outside, and the single-layer heating furnace is pressed while continuously pressing the laminated continuum having a plurality of openings on the back material side from the upper and lower surfaces thereof. A method for producing a phenolic resin foam panel, wherein the curing reaction is completed at the same time as closing the resin layer portions of the plurality of openings. 2. The method according to claim 1, wherein the continuous perforating step by the perforator is performed between a gel time and a rise time, which are phenol resin curing reaction steps in a single heating furnace. A method for manufacturing a phenolic resin foam panel. 3. A foamed phenolic resin mixture is discharged onto a surface material that is continuously transferred, and a backside material is further continuously supplied on the resin mixture to form a laminated continuous body. A plurality of openings penetrating through the back material and the resin layer are continuously formed by passing the laminated continuous body through a single heating furnace while pressing the laminated continuous body from the upper and lower surfaces thereof, and using a punching machine installed in the middle of the single heating furnace. Provided, the gas component staying inside the laminated continuum is instantaneously released to the outside, and the single-layer heating furnace is pressed while continuously pressing the laminated continuum having a plurality of openings on the back material side from the upper and lower surfaces thereof. A phenolic resin foam panel manufactured by a manufacturing method that completes a curing reaction at the same time as closing the resin layer portion of the plurality of openings. 4. A foamable phenolic resin mixture is discharged onto the surface material being continuously transferred, and a backside material is continuously laminated and supplied on the resin mixture to form a laminated continuous body. A plurality of openings penetrating through the back material and the resin layer are continuously formed by passing the laminated continuous body through a single heating furnace while pressing the laminated continuous body from the upper and lower surfaces thereof, and using a punching machine installed in the middle of the single heating furnace. Provided, the gas component staying inside the laminated continuum is instantaneously released to the outside, and the single-layer heating furnace is pressed while continuously pressing the laminated continuum having a plurality of openings on the back material side from the upper and lower surfaces thereof. A continuous production apparatus for a phenolic resin foam panel, wherein the curing reaction is completed at the same time as closing the resin layer portion of the plurality of openings.